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Spike Systems: PBG System Family Installation

20

Figure 15 – Inductive Loop Vehicle Detector (Saw Cut Loop) Beneath Cabinet

Refer to   Appendix B   for further information   on   the Optional Inductive Vehicle Detector
installation.

Note -‐-‐ Ensure there is enough spare   loop wire   by leaving at least 12 inches of slack (beyond
what is required to reach the control panel termination point) as a service loop.

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Summary of Contents for PBG Series

Page 1: ...ms PBG System Family Installation PBG 100 120 140 160 SYSTEM MANUAL Automated Motorized Hydraulic Traffic Controller Spike Systems 3623 S Seventh Street Phoenix Arizona 85040 Phone 602 243 0291 Fax 60...

Page 2: ...Spike Systems PBG System Family Installation This manual describes the operational requirements of the PBG Hydraulic Traffic Control System as it is normally configured on site...

Page 3: ...hicle Detector as Preparation for Installation 19 2 8 Plate and Cabinet Placement and Preparation Left Hand Shown 21 2 8 1 Position the Control Cabinet Close to the and Plate Barrier 24 2 8 2 Position...

Page 4: ...ions for Installation Planning 4 Figure 2 PBG Product Family Major Component Identification 5 Figure 3 PBG 120 Universal Layout and Configuration 6 Figure 4 PBG 100 RH DB Right Handed Double Buttress...

Page 5: ...gure 27 Pulling Two Hydraulic Hoses Through PBG Control Cabinet 28 Figure 28 Two Hoses Routed to Non Control Cabinet 29 Figure 29 Placing Track in Position Above Hoses 29 Figure 30 Minor Positional Ad...

Page 6: ...Top and Without Bottom Covers Removed 47 Figure 54 Siemens PLC Wiring Scheme 48 Figure 55 Schneider LC1 D25 Relay Control Cabinet 49 Figure 56 TB 1 Terminal Block Installation Wiring Control Cabinet...

Page 7: ...ion Non Control Cabinet 66 Figure 72 Clevis Installation Control Cabinet 67 Figure 73 Hydraulic Cylinder Installation Control Cabinet 68 Figure 74 Hydraulic Cylinder Installation Non Control Cabinet 6...

Page 8: ...Spike Systems PBG System Family Installation vi...

Page 9: ...parts of this manual WARNING POTENTIALLY LIFE THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO OPERATE SERVICE OR MAKE ADJUSTMENTS TO THE HYDRAULIC T...

Page 10: ...trol Cabinet on the right or left side with NO Non Control Cabinet Also two PBG 100 systems can be combined with a Control Cabinet on each side and no Non Control Cabinets for a total Clear Width of 2...

Page 11: ...ol High Security Card Readers Key Lock Switch Directional Indication System 1 4 Right or Left Side Configuration All PBG system configurations are shipped from the factory as either a right or left ha...

Page 12: ...PBG 100 As Installed and Dimensions for Installation Planning PBG 100 Clear Width Plate Width System Width Slab Width Depth 10 120 11 13 14 50 PBG 120 Clear Width Plate Width Overall Width Slab Width...

Page 13: ...is hardware on the inside of the Control Cabinet and one to the clevis on the inside of the Non Control Cabinet The lower ends of hydraulic cylinders are to be attached to welded clevis assemblies on...

Page 14: ...Spike Systems PBG System Family Installation 6 1 6 Configuration Options of the PBG Family 1 6 1 Standard Layout Universal Figure 3 PBG 120 Universal Layout and Configuration...

Page 15: ...Spike Systems PBG System Family Installation 7 1 6 2 Sample PBG 100 Layout Figure 4 PBG 100 RH DB Right Handed Double Buttress...

Page 16: ...Spike Systems PBG System Family Installation 8 1 6 3 Sample PBG 120 RH and LH Layout Figure 5 PBG 120 LH DB Left Handed Double Buttress Figure 6 PBG 120 RH DB Right Handed Double Buttress...

Page 17: ...Spike Systems PBG System Family Installation 9 Figure 7 PBG 120 RH DB Right Handed Double Buttress...

Page 18: ...Spike Systems PBG System Family Installation 10 1 6 4 Sample PBG 160 RH and LH Layout Figure 8 PBG 160 LH DB Left Handed Double Buttress...

Page 19: ...Spike Systems PBG System Family Installation 11 1 6 5 Sample PBG 100 Special Layouts Figure 9 PBG 100 LH SB Left Handed Single Buttress...

Page 20: ...Spike Systems PBG System Family Installation 12 Figure 10 PBG 100 LH RH DB Left Right Handed Double Buttress...

Page 21: ...Spike Systems PBG System Family Installation 13 Figure 11 PBG 100 LH RH DB Left Right Handed Double Buttress Typical Lane Layout with Maximum System Gap...

Page 22: ...Spike Systems PBG System Family Installation 14 INTENTIONALLY BLANK...

Page 23: ...process Detailed information on these systems can be found on the Internet at https magneticgateopeners com store pdfs microdrive manual pdf 2 2 Installation Preparation System Unpacking All PBG syst...

Page 24: ...or to any installation process ensure that the area where the Spike System is to be installed is free of any debris to ensure that all components rest squarely on the ground Tool Required Tool Type To...

Page 25: ...Spike Systems PBG System Family Installation 17 Figure 13 Inner Panel Removal from Control and Non Control Cabinets Tool Required Tool Type Tool Specification Wrench Socket 7 16...

Page 26: ...Pre Installation Considerations Inductive Loop Vehicle Detector If the installation is to include an Inductive Control Loop Detector the rectangular loop should be cut and prepared prior to the syste...

Page 27: ...cification Forklift for unit placement If a forklift is not available use sufficient labor to lift and place the Control Cabinet in position Mark the path for saw cut underneath where cabinet will be...

Page 28: ...Cut Loop Beneath Cabinet Refer to Appendix B for further information on the Optional Inductive Vehicle Detector installation Note Ensure there is enough spare loop wire by leaving at least 12 inches o...

Page 29: ...board down to protect the PBG plate from being scratched or marred by the concrete surface Take great care in placing the plate to ensure that it is precisely located where it will be installed perman...

Page 30: ...Spike Systems PBG System Family Installation 22 Figure 17 Wood Blocks Used Under the Plate 3 Locations 1 of 3 Figure 18 Wood Blocks Used Under the Plate 3 Locations 2 of 3...

Page 31: ...Spike Systems PBG System Family Installation 23 Figure 19 Wood Blocks Used Under the Plate 3 Locations 3 of 3...

Page 32: ...the and Plate Barrier Place the Control Cabinet near the Hinge and Plate Assemblies In the figure below a Left Handed configuration is shown Figure 20 Locate Control Cabinet near the Plate and Hinge f...

Page 33: ...ion Forklift for unit placement If a forklift is not available use sufficient labor to lift and place the Control Cabinet in position Figure 22 Locate Non Control Cabinet near the Plate and Hinge for...

Page 34: ...the Hydraulic Cylinders to the Plate Barrier in two places right and left sides of Plate as shown below Figure 23 Secure Hydraulic Cylinder to Plate 2 sides Figure 24 Hardware for Mounting Hydraulic...

Page 35: ...are attached to the Hydraulic Cylinder in the Non Control Cabinet The two hoses that are to be threaded through the track are coiled up in the Control Cabinet as shown below Start this portion of the...

Page 36: ...Spike Systems PBG System Family Installation 28 Figure 26 Two Hoses Routed Through Track to Non Control Cabinet Figure 27 Pulling Two Hydraulic Hoses Through PBG Control Cabinet...

Page 37: ...ystems PBG System Family Installation 29 Figure 28 Two Hoses Routed to Non Control Cabinet Figure 29 Placing Track in Position Above Hoses BE VERY CAREFUL TO NOT PINCH EITHER HOSE WHEN POSITIONING THE...

Page 38: ...sure that the RED coded hose is attached to the RED coded location on the hydraulic cylinder in the Non Control Cabinet In a similar fashion ensure that the GREEN coded hose is attached to the GREEN c...

Page 39: ...Spike Systems PBG System Family Installation 31 Figure 31 Hydraulic Hose Connection Non Control Cabinet Tool Required Tool Type Tool Specification Wrench 9 16 to attach Hydraulic Hoses 2 locations...

Page 40: ...Spike Systems PBG System Family Installation 32 Figure 32 Hydraulic Hose Connection Control Cabinet Figure 33 Hydraulic Hose Connection Non Control Cabinet...

Page 41: ...trol Cabinets and the PBG Track 3 2 Installation of Concrete Anchors 3 2 1 System View Prior to Anchor Installation Before concrete anchors are installed the PBG system should resemble the figure belo...

Page 42: ...allation Spike PBG systems are anchored to the ground with Hilti 4 x 5 8 concrete anchors as shown in Figure 49 Use a 5 8 masonry drill bit to pilot holes for the anchors at least 4 inches deep Remove...

Page 43: ...ammer Drill or similar for concrete drilling Concrete Bit 5 8 masonry bit Drill a minimum depth of 4 Air Compressor or similar To remove dust and debris from drilling Wrench Socket 15 16 Concrete Anch...

Page 44: ...Spike Systems PBG System Family Installation 36 Figure 38 Cleaning Pilot Holes After Drilling Figure 39 Secure Anchors with Wrench for Final Attachment...

Page 45: ...ontact with upper limit switch in the Control Cabinet Note that the Non Control Cabinet does not have limit switches It may be necessary to make a slight adjustment to the upper control limit switch l...

Page 46: ...Spike Systems PBG System Family Installation 38 Figure 41 Location of Upper Limit Switch Control Cabinet Figure 42 Location of Lower Limit Switch Control Cabinet Reference Only...

Page 47: ...ype Tool Specification Wrench Socket 7 16 3 5 AC Power Connection The client supplied power is to be connected to the 4 gang junction box via flexible conduit The flexible conduit and power wires are...

Page 48: ...ion Box Inside Control Cabinet Tool Required Tool Type Tool Specification Flexible Conduit To connect power conduit stub up to 4 gang box Conduit Fitting To connect flexible conduit to client installe...

Page 49: ...Figure 45 Location of Flexible Conduit Installation to AC Junction Box Note The bend in the flexible conduit should be more gradual than depicted above 3 6 Traffic Control Signal Mounting Figure 46 T...

Page 50: ...attachment at the control panel Tool Required Tool Type Tool Specification Channel Locks Large size to secure mounting hardware Figure 48 Assembled Traffic Control Mounting Adapter Control Cabinet 3...

Page 51: ...t Small Wire Strippers If required for cable connection 3 7 Wiring for Remote Operating Switch Guard Shack Typically As indicated in the figure below a field connection barrier operated switch or cont...

Page 52: ...G System Family Installation 44 Figure 50 Installation Location of Field Connection Barrier Operator Tool Required Tool Type Tool Specification Screw Driver Flat Small Wire Strippers If required for c...

Page 53: ...Spike Systems PBG System Family Installation 45 Figure 51 Limit Switch Wiring Usually Performed at Factory...

Page 54: ...Callout Component A Siemens S7 1200 PLC B Schneider Control Relay LC1 D25 C Momentary On Off Toggle Switch D TB2 Terminal Block E TB1 Terminal Block F Hydraulic Fluid Reservoir G Leeson 1 5 HP Motor P...

Page 55: ...Spike Systems PBG System Family Installation 47 Figure 53 Siemens S7 1200 PLC Control Cabinet With Top and Without Bottom Covers Removed...

Page 56: ...Spike Systems PBG System Family Installation 48 Figure 54 Siemens PLC Wiring Scheme...

Page 57: ...Spike Systems PBG System Family Installation 49 Figure 55 Schneider LC1 D25 Relay Control Cabinet...

Page 58: ...Spike Systems PBG System Family Installation 50 Figure 56 TB 1 Terminal Block Installation Wiring Control Cabinet...

Page 59: ...Spike Systems PBG System Family Installation 51 Figure 57 TB 1 Terminal Block Factory Wiring Control Cabinet...

Page 60: ...Spike Systems PBG System Family Installation 52 Figure 58 TB 2 Terminal Block Factory Wiring Control Cabinet...

Page 61: ...Spike Systems PBG System Family Installation 53 Figure 59 TB 2 Terminal Block Installation Wiring Control Cabinet...

Page 62: ...Spike Systems PBG System Family Installation 54 Figure 60 Momentary On Off Operation Switch Wired at Factory Control Cabinet...

Page 63: ...BG System Family Installation 55 Figure 61 Momentary Switch in OFF or Neutral Position Figure 62 Momentary Switch in Up Raise Gate or Barrier Plate Figure 63 Momentary Switch for DOWN or Lower Gate or...

Page 64: ...Spike Systems PBG System Family Installation 56 Figure 64 Left Side Electrical Schematic Control Cabinet...

Page 65: ...Spike Systems PBG System Family Installation 57 Figure 65 Right Side Electrical Schematic Control Cabinet...

Page 66: ...Spike Systems PBG System Family Installation 58 Figure 66 Entire Electrical Schematic Control Cabinet...

Page 67: ...Spike Systems PBG System Family Installation 59 Figure 67 Motor Pump and Fluid Reservoir Control Cabinet...

Page 68: ......

Page 69: ...he system operation be tested using the manual operating switch located on the outside of the electronic control compartment within the Control Cabinet This switch is identified in the figure below Wh...

Page 70: ...irection of the indication will result in shaft seal damage All electric connections should be done according to local standards Failure to comply with local standards and use of non certified compone...

Page 71: ...tor Therefore the pump flow cannot be adjusted The adjustment for the pressure relief valve will adjust pressure only It will not increase pump flow The relief valve is set to a pressure specified whe...

Page 72: ...e Material Part Numbers Description Brand Part No Quantity Hydraulic Fluid DEXRON III ATF Fluid HO 2 3 Liters 4 4 Possible Field Repair Tasks The following sections provide information on possible fie...

Page 73: ...e Systems PBG System Family Installation 65 Figure 70 Replacing a Damaged Plate to a Non Damaged Hinge Assembly Tool Required Tool Type Tool Specification Wrench Socket 9 16 for bolt Allen Wrench for...

Page 74: ...Spike Systems PBG System Family Installation 66 4 4 2 Clevis Installation Non Control Cabinet Figure 71 Clevis Installation Non Control Cabinet...

Page 75: ...Cabinet Using nuts washers and bolts four each install a clevis to the inner wall of the Control Cabinet as indicated in the illustration below Figure 72 Clevis Installation Control Cabinet Tool Requi...

Page 76: ...ystem Family Installation 68 4 4 4 Hydraulic Cylinder Installation Control and Non Control Cabinet Figure 73 Hydraulic Cylinder Installation Control Cabinet Figure 74 Hydraulic Cylinder Installation N...

Page 77: ...0 VAC Pump Terminal 50 X Pump Power 110 VAC Gate Access Controller Input 24 VDC Terminal No PLC Address Description Voltage Notes 30 X Fuse block F4 24 VDC fusing PLC power supply to PLC L 24 VDC Fuse...

Page 78: ...arm controller signal open dry contact N A No power from controller 6 DQb 0 Gate arm controller signal closed dry contact N A No power from controller 7 DQa 0 Solenoid Control Valve down open Extend...

Page 79: ...Switch Brown 32 Up Limit Switch Black 30 DIa L 31 PLC DIa M 24VDC PLC DIa 1M Down Limit Switch Blue Up Limit Switch Brown 22 NC 21 NC 20 PLC DIa 5 19 PLC DIa 4 19 Jumper 32 Blue 23 NC 18 PLC DIa 3 Up...

Page 80: ...d Junction Box Green Wire 35 Loop Detector Socket Pin 1 Black 34 Pump Black Wire 49 Switched Junction Box AC N White 47 Directional Control Valve 47 Directional Control Valve 47 Control Loop Socket 2...

Page 81: ...3 NC 4 NC 5 Output Relay Common TB 1 32 6 Output Relay Normally Open Closes for DETECT TB1 16 7 Loop Input TB1 25 8 Loop Input TB1 24 9 NC 10 NC 11 NC Schneider LC1 D25 Relay A1 Siemens PLC DQa 2 Red...

Page 82: ...Spike Systems PBG System Family Installation 74...

Page 83: ...lity of the customer The warranty is voided if any modifications changes or additions to the equipment are performed without written approval from Spike Systems In addition this warranty may be voided...

Page 84: ......

Page 85: ...angle Dimensions PBG 100 10 32 48 x 6 PBG 120 12 32 48 x 6 PBG 140 14 32 48 x 6 or custom size Note 1 PBG 160 16 32 48 x 6 or custom size Note 1 Note 1 All systems that include an Inductive Loop Vehic...

Page 86: ...ection The figure below indicates the location where the Inductive Vehicle Loop Detection module is to be attached within the electronic control panel The pins on this device are keyed so that there i...

Page 87: ...Spike Systems PBG System Family Installation 79 Figure 76 Typical Inductive Vehicle Detection Module Saw Cut Control...

Page 88: ...ly Installation 80 Figure 77 Wiring of Optional Inductive Vehicle Detection Module Saw Cut Control Control Cabinet Tool Required Tool Type Tool Specification Screw Driver Flat Small Wire Strippers If...

Page 89: ...the barricade completely while waiting to pull into or out into traffic 3 The closing and opening actions must be observed The mounting of operating switches or signals outside the field of direct vie...

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